Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1 Disconnect the negative battery terminal to prevent an accidental short circuit. 2 Unclip and remove the trim panel surrounding the radio and includ- ing the a/c vents. (Figure A) 3 Remove (4) Phillips screws securing the radio. (Figure B) 4 Disconnect and remove radio. (Figure B) Continue to KIT ASSEMBLY. 1 KIA RIO: Cut and remove shaded areas #1. (Figure A) HYUNDAI ACCENT: Cut and remove shaded areas #2. (Figure A) 2 Slide the DIN cage into the Radio Housing and secure by bending the metal locking tabs down. (Figure B) 3 Slide the aftermarket head unit into the cage until secure. (Figure C) Continue to final assembly.

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REMOVAL 1. Disconnect negative battery cable. 2. Loosen power steering lock bolts and nuts accordingly and remove tension from Power Steering (P/S) and/or Air Conditioning (A/C) compressor drive belt. 3. Remove P/S and/or A/C drive belt. 4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts. 6. Remove water pump pulley. 7. Remove crankshaft pulley and timing belt guide plate. 8. Remove upper and lower timing belt covers. 9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine. 10. Check that “I” mark on intake camshaft pulley is aligned with mark on cylinder head cover and “E” mark on exhaust camshaft pulley is aligned with mark on cylinder head cover. NOTE: Do not move camshaft or crankshaft once timing marks have been correctly positioned. 11. Loosen tensioner pulley lock bolt. 12. Protect timing belt with a rag. 13. Remove tensioner pulley. 14. Remove timing belt. NOTE: Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation. INSPECTION NOTE: Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt. 1. Replace timing belt if it is contaminated with oil or grease.

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COMPONENT DISASSEMBLY 1. Drain the coolant and disconnect the upper radiator hose. 2. Remove the breather hose (between the air cleaner and the head cover). 3. Remove the air-intake hose. 4. Remove the vacuum hose, fuel hose and coolant hose 5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. 6. Remove the ignition coil. 7. Remove the power steering oil pump and bracket. 8. Remove the intake manifold. 9. Remove the heat protector and exhaust manifold assembly. 10. Remove the coolant pump pulley and the crankshaft pulley. 11. Remove the timing belt cover. 12. Remove the timing belt tensioner pulley. 13. Remove the timing belt. 14. Remove the head cover and cam carrier assembly. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool, Cylinder Head Bolt Wrench, in the sequence as shown in the illustration in two or three steps. 16. Remove the gasket pieces from cylinder block top surface and cylinder head bottom surface. NOTE: Make sure that the gasket pieces do not fall in the engine INSPECTION 1. Clean all components. 2. Remove gasket fragments, dirt, oil, grease, carbon, moisture, residue, and other foreign materials. CYLINDER HEAD

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2. Loosen power steering lock bolts and nuts accordingly and remove tension from Power Steering (P/S) and/or Air Conditioning (A/C) compressor drive belt. 3. Remove P/S and/or A/C drive belt. 4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts. 6. Remove water pump pulley. 7. Remove crankshaft pulley and timing belt guide plate. 8. Remove upper and lower timing belt covers. 9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.10. Check that “I” mark on intake camshaft pulley is aligned with mark on cylinder head cover and “E” mark on exhaust camshaft pulley is aligned with mark on cylinder head cover. NOTE: Do not move camshaft or crankshaft once timing marks have been correctly positioned. 11. Loosen tensioner pulley lock bolt. 12. Protect timing belt with a rag. 13. Remove tensioner pulley. 14. Remove timing belt. NOTE: Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation. INSPECTION NOTE: Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt. 1. Replace timing belt if it is contaminated with oil or grease.